Friction-based recycling: an evaluation of friction extrusion for fabricating Ti-6Al-4 V wire fabricated from machining chip feedstock

Chouhan, Devesh Kumar; Komarasamy, Mageshwari; Taysom, Scott Brandon; Overman, Nicole R.; Canfield, Nathan L.; Roosendaal, Timothy J.; Reynolds, Anthony P.; Whalen, Scott A.

doi:10.1007/s00170-025-15147-0

Friction-based recycling: an evaluation of friction extrusion for fabricating Ti-6Al-4 V wire fabricated from machining chip feedstock

Journal Article · Wed Mar 05 00:00:00 EST 2025 · The International Journal of Advanced Manufacturing Technology

DOI:https://doi.org/10.1007/s00170-025-15147-0· OSTI ID:2526682

^[1]; Komarasamy, Mageshwari ^[1]; ^[1]; Overman, Nicole R. ^[1]; Canfield, Nathan L. ^[1]; Roosendaal, Timothy J. ^[1]; Reynolds, Anthony P. ^[2]; Whalen, Scott A. ^[1]

Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)
Pacific Northwest National Laboratory (PNNL), Richland, WA (United States); Univ. of South Carolina, Columbia, SC (United States)

Titanium and its alloys are used in aviation and automobile industries due to their remarkable strength to weight ratio, but machining loss commonly is high with ~ 80 wt% of the material being converted to scrap. Recycling post-consumer Ti scrap directly into solid bulk products is a potential solution for repurposing valuable material. Further, eliminating fresh Ti sponge during recycling might lead to lower energy and greenhouse gas emissions. In this study, a solid-phase process known as friction extrusion was utilized to recycle Ti-6Al-4 V machining chips into solid wires which could be used as feedstock in additive manufacturing. The friction consolidation technique was first used to convert chips with varying degrees of oxygen content into solid billets for its use as feedstock material in subsequent friction extrusion. The extrudates were fabricated above the beta transition temperature, which was achieved by selecting the rotation rate and feed rate, to process the billets near 1000 °C using a tungsten-lanthana extrusion die. This work presents the first occurrence of friction extruded titanium alloy wires. The effect of friction extrusion on microstructural features, tensile properties, and texture are reported. Overall, the friction extrusion method is capable of directly recycling Ti-6Al-4 V scrap into extruded wire.

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Research Organization:: Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)

Sponsoring Organization:: USDOE

Grant/Contract Number:: AC05-76RL01830

OSTI ID:: 2526682

Alternate ID(s):: OSTI ID: 2586540

Report Number(s):: PNNL-SA--204563

Journal Information:: The International Journal of Advanced Manufacturing Technology, Journal Name: The International Journal of Advanced Manufacturing Technology Journal Issue: 5-6 Vol. 137; ISSN 0268-3768; ISSN 1433-3015

Publisher:: Springer Science and Business Media LLCCopyright Statement

Country of Publication:: United States

Language:: English

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